Metal-ceramic composite and method for making same

Abstract

The composite of the present invention comprises a layer of ceramic having completely imbedded therein a metal grid, such composite having been made by coating a metal grid with a viscous ceramic slurry and thereafter firing to form the ceramic to a unitary structure. At the temperature to which the composite is fired to form the unitary structure the metal grid is in an expanded condition because of its high coefficient of thermal expansion, and upon cooling the metal grid is put into tension thereby putting the ceramic in compression. The composite is used as a liner for a metal wall which is cast with the liner in situ and is disclosed as having a hollow shape about which the cast wall extends in a manner having particular utility for insulated components of internal combustion engines.

I claim: 
     
       1. An insulated component for an internal combustion engine comprising: a cast metal engine component wall that is heated during engine operation; a metal-ceramic liner of a hollow shape about which the wall extends in direct engagement therewith; said metal wall being cast about said hollow metal-ceramic liner with the liner in situ; said metal-ceramic liner including a monolithic layer of ceramic material formed from a slurry and having imbedded therein a metal grid including openings which are closed by said ceramic material; and said metal grid having a melting temperature higher than the temperature at which the slurry forms into said monolithic ceramic layer and having a higher coefficient of thermal expansion than the ceramic material. 
     
     
       2. An insulated component for an internal combustion engine comprising: a cast metal engine component wall that is heated during engine operation; a metal-ceramic liner of a hollow shape about which the wall extends in direct engagement therewith; said liner including a plurality of layers spaced from each other; said metal wall being cast about said hollow metal-ceramic liner with the liner in situ; said metal-ceramic liner including a monolithic layer of ceramic material formed from a slurry and having imbedded therein a metal grid including openings which are closed by said ceramic material; and said metal grid having a melting temperature higher than the temperature at which the slurry forms into said monolithic ceramic layer and having a higher coefficient of thermal expansion than the ceramic material.